ENGINE UNIT REASSEMBLY

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL TURBO WATER HOSE UNION (for Variable Nozzle Vane Turbocharger)

    Note

    If coolant leaks from a turbo water hose union or a turbo water hose union is corroded, replace the turbo water hose union.


    1. Clean the cylinder block side hole and new turbo water hose union with non-residue solvent.

    2. A01DY19E02
      Text in Illustration
      *a Front
      *b 5.0 mm (0.197 in.)
      *c 2.0 mm (0.787 in.)
      *d Adhesive

      Apply adhesive onto the shaded area of a turbo water hose union as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the turbo water hose union within 3 minutes after applying adhesive.

    3. Set the turbo water hose union and tap it until the edge of the turbo water hose union fits against the chamfered part of the cylinder block as shown in the illustration.

  2. INSTALL CYLINDER BLOCK WATER DRAIN COCK PLUG (for Waste Gate Type Turbocharger)


    1. Clean the cylinder block side hole and new cylinder block water drain plug with non-residue solvent.

    2. A01DWH5E03
      Text in Illustration
      *a Front
      *b 5.0 mm (0.197 in.)
      *c 2.0 mm (0.787 in.)
      *d Adhesive

      Apply adhesive onto the shaded area of a cylinder block water drain plug as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the cylinder block water drain plug within 3 minutes after applying adhesive.

    3. Set the cylinder block water drain plug and tap it until the edge of the cylinder block water drain plug fits against the chamfered part of the cylinder block as shown in the illustration.

  3. INSTALL TIGHT PLUG


    1. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Do not start the engine for 1 hour after installation.

    2. Position A:

      Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

    3. Other positions:

      Using SST and a hammer, tap in the tight plugs as shown in the illustration.

      Position B

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )

      Position C

      SST
      09950-60010   ( 09951-00190 )
      09950-70010   ( 09951-07100 )

      Position D

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position E and H

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

      Position F

      SST
      09950-60010   ( 09951-00400, 09951-00450 )
      09950-70010   ( 09951-07100 )

      Position G

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )
      A01DVSKE05
      Text in Illustration
      *1 Stops - -
      *a Right Side *b Left Side
      *c Front Side *d Rear Side

  4. INSTALL STUD BOLT


    1. Install the stud bolts.

      A01E23VE01
      Text in Illustration
      *a Front Side *b Left Side
      *c Oil Pan Side *d Right Side

  5. INSTALL STRAIGHT PIN


    1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

      Standard Protrusion Height
      Item Specified Condition
      Pin A 7.5 mm (0.295 in.) or less
      Pin B 6 mm (0.234 in.) or less
      Pin C 12 mm (0.472 in.) or less
      A01DYOKE01
      Text in Illustration
      *1 Pin A *2 Pin B
      *3 Pin C *4 Protrusion height
      *a Front Side *b Rear Side

  6. INSTALL RING PIN


    1. Using a plastic-faced hammer, tap in new ring pins to the cylinder block.

      Standard Protrusion
      6 mm (0.236 in.) or less
      A01E01RE01
      Text in Illustration
      *a Cylinder Head Side *b 6 mm (0.236 in.) or less

  7. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. Install a new gasket and the screw plug.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  8. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Align the pin of the oil nozzle with the pin hole of the cylinder block.

    2. Install the 4 oil nozzles together with the check valves.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  9. INSTALL PISTON PIN


    1. Assemble the piston and connecting rod.


      1. A01DVXUE01

        Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

      2. Gradually heat the piston to about 60°C (140°F).

      3. Coat the piston pin with engine oil.

      4. A01DYFUE01
        Text in Illustration
        *1 Front Mark (Arrow)
        *2 Front Mark (Protrusion)

        Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      5. A01DUXQE01

        Check the fit between the piston and piston pin. Try to move the piston back and forth on the piston pin.

      6. A01E2PE

        Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

    2. Install the piston rings.


      1. A01E2AOE01
        Text in Illustration
        *1 Coil Joint
        *2 Oil Ring End Gap

        Install the coil and oil ring by hand.

        Tech Tips

        Face the end gap of the oil ring in the opposite direction of the coil joint.

      2. A01DZUNE01
        Text in Illustration
        *1 No. 1 Piston Ring
        *2 No. 2 Piston Ring

        Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

        Code mark
        Number Mark
        No. 1 Piston Ring w/o EGR system NP
        for Waste Gate Type Turbocharger 1N or N1
        for Variable Nozzle Vane Turbocharger 1VN
        No. 2 Piston Ring N2
      3. A01DVJRE01
        Text in Illustration
        *A Waste gate Type Turbocharger
        *B Variable Nozzle Vane Turbocharger
        *1 No. 1 Piston Ring
        *2 Oil Ring
        *3 Coil
        *4 No. 2 Piston Ring
        *5 Front Mark (Arrow)

        Position the piston rings so that the ring ends are as shown.

        Note

        Do not align the ring ends.

  10. INSTALL CONNECTING ROD BEARING


    1. A01DZS0E01

      Align the bearing claw with the groove of the connecting rod or connecting cap.

    2. Install the bearings to the connecting rod and connecting rod cap.

  11. INSTALL CRANKSHAFT BEARING

    Tech Tips

    Upper bearings have an oil groove and oil hole. Lower bearings do not.


    1. A01E213E01

      Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

    2. A01DV1HE01

      Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

  12. INSTALL CRANKSHAFT


    1. Place the crankshaft on the cylinder block.

    2. Install the 2 upper thrust washers to the No. 5 journal position of the cylinder block.


      1. A01E1TUE02

        Push the crankshaft toward the front (rear) side.

      2. Install the 2 thrust washers with the oil grooves facing outward.

    3. A01DVC3E03

      Install the 2 thrust washers on the No. 5 bearing cap with the grooves facing outward.

    4. A01DZCNE01

      Install the 5 crankshaft bearing caps in their proper locations.

    5. Install the crankshaft bearing cap bolts.

      Tech Tips


      • The main bearing cap bolts are tightened in 2 progressive steps.

      • If a main bearing cap bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil to the threads and under the bolt heads of the main bearing caps.

      2. A01DVTVE07

        Install and uniformly tighten the 10 bolts of the main bearing caps in several passes in the sequence shown in the illustration.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

        If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.

      3. A01DW4ZE08
        Text in Illustration
        *1 Painted Mark
        *a Front

        Mark the front of the main bearing cap bolts with paint.

      4. Retighten the main bearing cap bolts 90° in the numerical order shown on previous page.

      5. Check that the painted marks are now at a 90° angle to the front.

    6. Check that the crankshaft turns smoothly.

    7. Check the crankshaft thrust clearance.

  13. INSTALL PISTON AND CONNECTING ROD


    1. A01DYKQE01
      Text in Illustration
      *1 Front Mark (Arrow)

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

    2. Place the connecting rod cap on the connecting rod.


      1. Match the numbered connecting rod cap with the connecting rod.

      2. A01DVAWE01

        Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

      3. A01DX3JE02
        Text in Illustration
        *1 Front Mark (Protrusion)
        A01E2TX Front

        Check that the front mark of the connecting rod cap is facing forward.

    3. Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts are tightened in 2 progressive steps.

      • If any connecting rod bolt is broken or deformed, replace it.


      1. Apply a light of engine oil on the threads and under the heads of the connecting rod cap bolts.

      2. A01DW42E01

        Install and alternately tighten the bolts of the connecting rod cap in several passes.

        Torque:
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }

        If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

      3. A01DYYDE05
        Text in Illustration
        *1 Painted Mark
        *a Front

        Mark the front of the connecting rod cap bolts with paint.

      4. Retighten the connecting rod cap bolts 90° as shown.

      5. Check that the painted marks are now at a 90° angle to the front.

    4. Check that the crankshaft turns smoothly.

    5. Check the connecting rod thrust clearance Click here.

  14. INSTALL CYLINDER BLOCK OIL ORIFICE

  15. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. Remove oil seal packing (FIPG) from oil pan and cylinder block.

    2. A01E22OE01

      Apply seal packing to the specific places described in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3 to 5 mm (0.12 to 0.20 in.)
      Text in Illustration
      *1 Seal Packing

      Note

      After applying FIPG, install the engine rear oil seal retainer within 3 minutes and tighten its bolts within 15 minutes.

    3. Install the retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  16. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01E2ASE05
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5 mm (0.20 in.)

      Note

      Install the timing gear case assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. A01E1H1E01
      Text in Illustration
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case.

    4. A01E2GZE04
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block groove of the timing gear case.

    5. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    6. A01DXR2E01

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf, for union bolt (A) }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for bolt }
    7. A01E2YEE01

      Remove the screw plug.

    8. Pour in approximately 20 cc (0.12 cu in.) of engine oil into the oil pump.

    9. Install a new gasket and the screw plug.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  17. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  18. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01E0W7E03

      Apply seal packing to the oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note

      Install the oil pan assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Install the oil level gauge sensor with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  19. INSTALL CRANKSHAFT TIMING GEAR


    1. Position the crankshaft timing gear with timing mark 1 facing forward.

    2. Align the key groove of the crankshaft timing gear with the set key on the crankshaft.

    3. A01DVITE01

      Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  20. INSTALL INJECTION GEAR


    1. Install a new O-ring and the supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Fit the key (protrusion) of the supply pump in the key slot of the injection gear.

    3. A01DWZSE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    4. A01DV5GE01

      Install the the injection gear set nut.

    5. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  21. INSTALL NO. 2 IDLE SUB GEAR


    1. A01E12GE01

      Using a cloth or equivalent, mount the No. 1 idle gear in a vise as shown in the illustration.

      Note

      Be careful not to damage the gear.

    2. A01DXLPE02
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Gear Spring
      *4 Pin

      Install the gear spring.

    3. Install the No. 2 idle sub gear.

      Tech Tips

      Align the pins on the gears with the spring ends.

    4. Install the wave washer.

    5. A01E01BE01

      Using snap ring pliers, install the snap ring.

    6. A01E16CE03
      Text in Illustration
      *1 Service Bolt
      *2 No. 1 Idle Gear
      *3 No. 2 Idle Sub Gear
      A01E2TX Turn

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise, and temporarily install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Recommended Service Bolt
      Thread diameter Thread pitch Bolt length
      6.0 mm (0.23 in.) 1.0 mm (0.03 in.) Approx. 19 mm (0.75 in.)

    7. Align the gear teeth of the No. 1 idle gear and No. 2 idle sub gear, and tighten the service bolt.

  22. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01DVPDE07
      Text in Illustration
      *1 Oil Hole

      Install the gear shaft as shown in the illustration

  23. INSTALL NO. 1 IDLE GEAR


    1. A01DW82E04
      Text in Illustration
      *a Turn

      Align the "5" timing marks of the idle gear and crankshaft timing gear.

    2. Using SST, turn the injection and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. A01DZQ6E02

      Position the thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the thrust plate with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    5. Remove the service bolt.

  24. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the sensor plate with the set key.

    2. Install the sensor plate with the cupped side facing outward.

  25. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01DWHEE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3 to 5 mm (0.12 to 0.20 in.)

      Note

      After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

    3. A01DYKIE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the timing gear case.

    4. Install the timing gear cover with the 14 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  26. INSTALL WATER PUMP ASSEMBLY


    1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  27. INSTALL CYLINDER HEAD GASKET


    1. A01E1XTE02
      Text in Illustration
      *1 Measuring Tip
      *2 Protrusion

      Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

    2. A01DWGGE02
      Text in Illustration
      *1 Measuring Point

      Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

    3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

      Piston protrusion
      0.005 to 0.255 mm (0.0002 to 0.0100 in.)

      Tech Tips

      After installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DXBTE02
      Text in Illustration
      *1 Cutout Mark
      A01E2TX Front

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New Cylinder Head Gasket Thickness
      Mark Specified Condition
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

      1. Select the largest piston protrusion value from the measurements made. Then select a new gasket according to the table below.

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.005 to 0.054 mm (0.0002 to 0.0021 in.) 0.055 to 0.104 mm (0.0022 to 0.0041 in.) 0.105 to 0.154 mm (0.0041 to 0.0061 in.) 0.155 to 0.204 mm (0.0061 to 0.0080 in.) 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
        Gasket to be used A B C D E
    5. A01E1R6E02

      Place the cylinder head gasket on the cylinder block.

      Text in Illustration
      A01E2TX Front

      Note

      Make sure the gasket is installed facing the proper direction.

  28. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01E12RE01

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it Click here.


    1. Place the cylinder head on the cylinder head gasket.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    3. Install the 18 washers with the 18 cylinder head bolts, and uniformly tighten the bolts in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Standard Bolt Length
      Item Specified Condition
      A 110 mm (4.33 in.)
      B 167 mm (6.57 in.)

      If any one the cylinder head bolts does not meet the torque specification, replace it.

    4. A01DYXOE03
      *1 Painted Mark
      *a Front

      Mark the front of each cylinder head bolt with paint.

    5. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration.

    6. Tighten the cylinder head bolts by an additional 90°.

    7. Check that the painted marks are now facing rearward.

  29. INSTALL CAMSHAFT


    1. A01E2S9E02
      Text in Illustration
      *1 Key

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

    2. A01DXL7E04

      Install the camshaft.


      1. Apply engine oil to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head with the key groove facing upward.

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. A01DV15E01

        Align the timing marks (1-dot marks) of the camshaft drive and driven main gears and set the No. 2 camshaft in place.

    3. Remove any old seal packing (FIPG material) from the camshaft bearing cap.

    4. A01DYANE05
      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage

      Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow seal packing to contact the oil passage of the bearing cap.

      • After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after installation.

    5. A01E2XHE01

      Install the 5 bearing caps to their proper locations.

    6. A01E0JJE02

      Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    7. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    8. A01DV44E01

      Install a new camshaft oil seal.


      1. Apply MP grease to the lip of a new oil seal.

      2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.

        SST
        09608-06041

  30. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  31. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. A01DYB9E01

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a light amount of clean engine oil to 4 new O-rings.

    3. A01E0HXE07

      Install the O-ring to each injector as shown in the illustration.

    4. Insert the 4 injectors into the cylinder head.

      Note


      • At this time, insert the injector until it touches the nozzle sheet surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return an injector to the same place it was removed from.

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01DWZ6E05

      Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

      Tech Tips


      • Apply a light amount of engine oil to the threads and under the heads of the clamp bolts.

      • Be sure to install the washers in the direction shown in the illustration.

      Note


      • A01DV3XE04

      • The fork portion of the nozzle holder clamp must be set to the injector.

      • Before tightening the bolts, check that the No. 1 nozzle holder clamp is set properly.

      • To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at the following step.

      • When tightening the bolts, pay attention not to tilt the bolt and the clamp.

      • Do not reuse the washer.

      • If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01E2T3E01

      Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.

      If scratches or dents are present, replace the nozzle leakage pipe.

    9. A01DVA2E04

      Set the leakage pipe and 5 new gaskets in place.

    10. Apply a light amount of oil to the 4 injector hollow screws and union bolt.

    11. A01DZ37E01

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01DVZRE04

      Tighten the 4 hollow screws in order from 1 to 4.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    14. Tighten the union bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

    15. Remove the 4 injection pipes.

  32. CHECK FOR FUEL LEAKS

    A01E0SLE03

    1. Check that there are no leaks from the Nozzle leakage pipe connection.


      1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      2. Apply a light amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. A01DX5HE01

        Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that No bubbles form.

        SST
        09992-00242

        Note

        Before checking for leakage, be sure to remove the ball and spring in the check valve.

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, the No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled check valve on the engine.

  33. INSTALL CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    1. Install the cylinder block insulator to the cylinder head.

  34. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing (FIPG) to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying seal packing, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

    2. Clean the bolts and their holes.

    3. Apply adhesive to 2 or 3 threads at the end of each of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the No. 2 timing belt cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  35. INSTALL CAMSHAFT TIMING PULLEY


    1. Install the camshaft timing pulley.

    2. Install the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  36. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

    2. Remove any old seal packing (FIPG) material from the cylinder head.

    3. A01E1YSE03

      Apply seal packing to the specific areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the head cover within 3 minutes after applying seal packing.

      • Do Not start the engine for at least 2 hours after installing the seal packing.

    4. A01DZGHE01

      Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    5. Install 4 new nozzle holder seals.

    6. Connect the ventilation hose.

    7. A01E177

      Connect the 4 connectors and install the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  37. INSTALL OIL FILLER CAP SUB-ASSEMBLY